Due to the advantages of flexible manufacturing, roller hemming takes the place of conventional hemming methods in automotive industry. In this study, numerical analysis of roller hemming operation was investigated to predict process outputs. In order to build an acceptable model, simulations were performed using five different element formulations and the results were compared with experimental outputs. Based on the comparisons in terms of roll-in and deformation, simulations with fully integrated element formulation provide higher performance to predict the results. Furthermore, the role of bending angle was discussed and it was seen that bending angle has a major influence on undesired wrinkling formation as well as the development of hemming forces and plastic strain.